Roller bed for a conveyor belt system

ABSTRACT

A roller bed that is inserted between idlers in a conveyor belt system. The roller bed includes a base plate that is oriented substantially parallel to said surface of said conveyor belt. A first side plate on a first side of the base plate is oriented at an angle to the surface of the conveyor belt to support a first side of conveyor belt and cause the first side of the conveyor belt to be angled upwards with respect to a plane of the surface. Small diameter rollers, very closely spaced, are affixed to a surface of the first side plate to support the conveyor belt and reduce friction between the side plate and the conveyor belt. A second side plate on a second side of the base plate is oriented at an angle to the surface of the conveyor belt to support a second side of the conveyor belt and cause the second side of the conveyor belt to be angled upwards with respect to the plane of the surface. Rollers that are affixed to a surface of the second plate of the conveyor belt to support the conveyor belt and reduce friction between the side plate and the conveyor belt.

FIELD OF THE INVENTION

[0001] This invention relates to conveyor belt system. Moreparticularly, this invention relates to a bed for supporting a conveyorbelt. Still more particularly, this invention relates to a roller bedthat is inserted between idlers to support the conveyor with adding aslittle drag or friction as possible.

PROBLEM

[0002] It is common to use conveyor belts to move bulk materials fromone place to another. For example, power plants transport coal fromstorage piles into hoppers in a processing area using a series ofconveyor belts. One problem with the use of conveyor belts is spillageof material. A second problem with the use of conveyor belts is airpollution from dust. The access material and dust may be volatile andcan be ignited by any heat or spark introduced into the environment.

[0003] Spillage of material typically occurs at a transfer point wherematerial is passed from one conveyor belt to a second conveyor belt. Thetransfer usually occurs by dropping the material from the first conveyorbelt to the second belt. As the material hits the second conveyor, thematerial sprays with some material falling over the edge of the secondconveyor belt. Vibrations caused by outside sources, such as motors, mayshake the conveyor belt and cause material to fall off the edges remotefrom the transfer point.

[0004] Air pollution is caused by induced air flow in a conveyor beltsystem. A stream of bulk material is formed by the material falling orbeing projected from the first conveyor belt to the second conveyorbelt. The individual particles in the stream of bulk materials impart africtional drag on the surrounding air. The surrounding air begins toflow in the direction of the material stream and attains a velocityapproaching the velocity of the material stream. This is called aninduced air flow. At the end of the fall, the bulk material is suddenlystopped and compacted caused by impact of the material stream onto thesecond conveyor belt. The velocity pressure of the induced air flow isconverted to static pressure by the impact of the bulk material. Aregion of high air pressure is created by the static pressure. Air inthe region of high air pressure must flow to a region of lower airpressure. As the air flows from the region of high air pressure to theregion of lower air pressure, small particles of the bulk material aresuspended in the air. In an open system, the movement of the air is fromhigh pressure to low pressure is evidenced by a dust cloud billowingfrom a loading point of the second conveyor belt.

[0005] It is common to use a housing to enclose the second conveyor beltand prevent the dust from billowing and reduce spillage. A skirtinghangs from the bottom edge of the housing and drags against the side ofthe conveyor belt to completely enclose the area. To maintain contactwith the skirting, a support is added underneath the conveyor belt.Typically, the support includes beams that run longitudinally with theconveyor belt along each side of the conveyor belt, or large rollsspaced apart on 12 to 18 inch centers. In the case of static bars, orbeams, it is a problem that these supports cause drag on the conveyorbelt. This drag causes undue exertion by a motor turning the conveyorbelt, wear of the skirting and wear of the belt. The drag may alsogenerate undesired heat which may melt the belt, or beams. Therefore, animproved manner of maintaining contact with the skirting is needed. Inthe case of large rolls on 12 plus inch centers, the belt will sagbetween the rolls and allow spillage, and impingement points wherematerial wedges between the belt and the wearliner, at each point wherethe belt sags between these rolls.

SOLUTION

[0006] The above and other problems are solved and an advance in thearts is made by the provision of a roller bed in accordance with thisinvention. A first advantage of a roller bed in accordance with thisinvention is that the bed cups the conveyor belt to prevent spillage. Asecond advantage of this invention is that side plates of the bed haverollers that support the conveyor belt. These rollers reduce frictionbetween the roller bed and belt. The rollers are placed with minimalspace between the rollers to prevent sag which may cause a gap betweenflexible skirting seals and the belt. A third advantage of thisinvention is that the angle of the side plates is adjustable to allow aroller plate of this invention to be placed in conveyor belt systems ofdifferent designs manufactured by varying companies.

[0007] In accordance with this invention, a roller bed that is insertedbetween idlers in a conveyor belt is designed in the following manner.The roller bed has a base plate oriented substantially parallel to asurface of the conveyor belt that carries material. A first side plateon a first side of the base plate is oriented at an angle to the surfaceof the conveyor belt and supports a first side of the conveyor belt tocause the side of the conveyor belt to be angled upwards with respect toa plane of the carrying surface of the conveyor belt. The first sideplate has rollers affixed to a contact surface of the first side plate.The rollers maintain contact with a skirting and reduce drag caused bythe support.

[0008] A second side plate on a second side of the base plate isoriented at an angle to the carrying surface of the conveyor belt andsupports a second side of the conveyor belt to cause the second side ofthe conveyor belt to be angled upwards with respect to the plane of thecarrying surface. Rollers affixed to a contact surface of the secondplate support the conveyor belt and reduce drag on the conveyor belt.

[0009] The base plate may also have rollers affixed to a contact surfaceof the base plate to prevent drag on the belt. This provides rollersunder on every plate to reduce drag on every surface of the belt.

[0010] In order to be inserted under belts having different designs madeby competing manufacturers, the first and second side plates may includeadjusting brackets that change the angle of orientation of the first andsecond side plates to conform to the angle created by idlers in theconveyor belt system. The adjusting brackets may include a base, asupport that extends upwards from the base, and a movable attachmentmember that affixes the first or the second side plate to the support ata desired angle. In a preferred embodiment, the movable attachmentmember has openings through the support in which a screw is threaded tosecure the side plate to the support.

[0011] The roller bed may be affixed to a mounting rail by couplings.The couplings may be a simple screw and threading arrangement.

[0012] The rollers mounted on the side plates are mounted with minimalspace between the rollers. The rollers may also be smaller in diameterthan idlers. The minimal space and smaller diameter reduces that amountof unsupported area underneath the conveyor belt. In a preferredexemplary embodiment, the rollers are of a small diameter and havesealed precision bearing to increase speed and reduce friction.

DESCRIPTION OF THE DRAWINGS

[0013] The above and other features of this invention are described inthe detailed description given below and the following drawings:

[0014]FIG. 1 illustrating a front view of a roller bed in accordancewith this invention;

[0015]FIG. 2 illustrating a front view of a roller bed inserted into aconveyor belt system in accordance with this invention;

[0016]FIG. 3 illustrating a side view of a side plate of a roller bed inaccordance with this invention;

[0017]FIG. 4 illustrating a front view of a side plate at a first angle;

[0018]FIG. 5 illustrating a front view of a side plate at a secondangle; and

[0019]FIG. 6 illustrating a front view of a side plate at a third angle.

DETAILED DESCRIPTION

[0020] In accordance with this invention, a roller bed is designed tosupport a conveyor belt between idlers. This roller bed is insertedbetween idlers that support a conveyor belt. The roller bed cups theconveyor belt between idlers to prevent spillage and presses theconveyor belt against skirting to prevent spillage and dust.

[0021]FIG. 1 illustrates a front view of a roller bed 100 supportingconveyor belt 104. Roller bed 100 has base plate 101, first side plate102 and second side plate 103. Base plate 101 supports a bottom carryingsurface of conveyor belt 104. First side plate 102 angles a first sideof conveyor belt 104 to cup conveyor belt 104 to prevent spillage andholds conveyor belt 104 against a skirt. Second side plate 103 angles asecond side of conveyor belt 104 to cup conveyor belt 104 to preventspillage and holds conveyor belt 104 against a skirt.

[0022] Base plate 101 is a platform which holds a carrying surface ofconveyor belt 104 flat. Base plate 101 provides an impact plate thatprevents conveyor belt 104 from buckling under the impact of material.Base plate 101 has a support surface oriented substantially parallel tothe carrying surface of conveyor belt 104. In the embodiment shown, asurface of base plate 101 that supports the carrying surface of conveyorbelt 104 is comprised of rollers 110. Rollers 110 are affixed to aplatform 113 via struts 111. Struts 111 are affixed to platform 113 bybolts 112 that thread through openings in platform 113 and struts 111.Rollers 110 are affixed to struts 111 by pins 114.

[0023] First side plate 102 is on a first side of base plate 101 and isoriented at an angle to the carrying surface of the conveyor belt. Firstside plate 101 supports a first side of conveyor belt and causes thefirst side of the conveyor belt to be angled upwards with respect to aplane of the surface of the conveyor belt. First side plate 102 includesrollers 120. Rollers 120 provide a contact surface for first side plate102. The rollers reduce drag and allow conveyor belt 104 to move alongwith less friction.

[0024] In the shown embodiment, rollers 120 are affixed to a platform141 by rails 137. Rails 137 are on opposing sides of platform 141 andare affixed to platform 141 via bolts and threaded openings. One skilledin the art will appreciate that other manners of affixing rollers 120 toplatform 141 are possible as well as other manners of affixing rails 137to platform 141.

[0025] Platform 141 is held in position by supports 122 and 129.Supports 122 and 129 affix to platform 113 on a first end and toplatform 141 on a second end. In the shown embodiment, supports 122 and129 are affixed to platform 113 by clamps. However, any other fasteningdevice may be used to affix supports 122 and 129 to platform 113.Supports 122 and 129 are affixed to platform 141 by bolts 126 threadedthrough openings. Although those skilled in the art will recognize thatany other form of fastener may be used.

[0026] In order to be inserted into several different designs ofconveyor belts, first side plate 102 has a movable attachment member129. Movable attachment member 129 allows the angle at which first sideplate 102 is set to be changed. In this embodiment, the movableattachment member is a plurality of threaded mated openings 125 on themovable attachment member through which a bolt 126 is inserted. However,one skilled in the art will recognize that other adjustable members maybe used, such as a pin.

[0027] Second side plate 103 is on a first side of base plate 101 and isoriented at an angle to the carrying surface of the conveyor belt.Second side plate 101 supports a second side of conveyor belt 104 andcauses the second side of conveyor belt 104 to be angled upwards withrespect to a plane of the carrying surface of the conveyor belt. Secondside plate 103 includes rollers 130. Rollers 130 provide a contactsurface for second side plate 103. The rollers 130 reduce drag and allowconveyor belt 104 to move along with less friction.

[0028] In the shown embodiment, rollers 130 are affixed to a platform142 by rails 137. Rails 137 are on opposing sides of platform 142 andare affixed to platform 142 via bolts and threaded openings. One skilledin the art will appreciate that other manners of affixing rollers 130 toplatform 142 are possible as well as other manners of affixing rails 137to platform 142.

[0029] Platform 142 is held in position by supports 132 and 139.Supports 132 and 139 affix to platform 113 on a first end and toplatform 142 on a second end. In the shown embodiment, supports 132 and139 are affixed to platform 113 by clamps. However, any other fasteningdevice may be used to affix supports 122 and 129 to platform 113.Supports 122 and 129 are affixed to platform 142 by bolts 136 threadedthrough openings. Although those skilled in the art will recognize thatany other form of fastener may be used.

[0030] In order to be inserted into several different designs ofconveyor belts, second side plate 103 has a movable attachment member139. Movable attachment member 139 allows the angle at which first sideplate 102 is set to be changed to fit under the desired belt. In thisembodiment, the movable attachment member is a plurality of threadedmated openings 135 on the movable attachment member through which a bolt136 is inserted. However, one skilled in the art will recognize thatother adjustable members may be used.

[0031]FIG. 2 illustrates cross sectional front view of conveyor system200 including roller bed 100 of FIG. 1. Conveyor system 200 includesskirt boards 107 and covering 108. Skirt boards 107 and covering 108enclose conveyor belt 104. Supports 109 affix skirt boards 107 to thebase of conveyor belt system 200. Conveyor stringers 150 affix rollerbed 100 to a base of conveyor system 200.

[0032] Skirtings 105 hang from a bottom end of skirt boards 107.Skirtings 105 brush against conveyor belt 104 to enclose conveyor belt104 and prevent material from spilling out of the enclosing. Skirtingseals 106 extend outward from skirtings 105 and further enclose conveyorbelt 104.

[0033]FIG. 3 illustrates a side view of a first side plate 102 tofurther show the configuration of first side plate 102 and second sideplate 103. First side plate 102 fits between idlers 300. Rails 127 affixto movable member 122 on an upper side and to support 129 on a lowerside. The upper side is the side of side plate 102 that is at the edgeof conveyor belt 104 and the lower side is proximate the center ofconveyor belt 104. FIG. 3 shows the angle side plate 102. FIG. 3 alsoshows that rollers 120 are rollers that have a smaller diameter thanidlers 300. This allows rollers 120 to be placed close together tominimize belt span between rollers 120 which in turn minimizes belt sag.The result is complete and even support between idlers 300.

[0034] In a preferred embodiment, the rollers 120 are of a smallerdiameter and has sealed precision bearings. This promotes a much bettersealing foundation forthe bed to prevent spillage.

[0035]FIGS. 4,5, and 6 illustrate first side plate 102 at a variety ofangles to fit under different conveyor belts. In FIG. 4, first sideplate 102 is in position 400 at a 45 degree angle with respect to theplane of the carrying surface of the conveyor belt. In the shownembodiment, first side plate 102 is placed in position 400 by insertingas bolt through a top most opening in movable attachment member 122. InFIG. 5, first side plate 102 is in position 500 which is at a 35 degreeangle with respect to the plane of the carrying surface of conveyor belt104. In the shown embodiment, first side plate 102 is placed in position500 by inserting as bolt through a middle opening in movable attachmentmember 122. In FIG. 6, first side plate 102 is in position 600 at a 20degree angle with respect to the plane of the carrying surface ofconveyor belt 104. In the shown embodiment, first side plate 102 isplaced in position 600 by inserting as bolt through a top most openingin movable attachment member 122.

[0036] The above is a description of a roller bed that is insertedbetween idlers in a conveyor in accordance with this invention. It ispossible that those skilled in the art will design alternative rollerbeds that infringe this roller bed as set forth in the claim beloweither literally or through the Doctrine of Equivalents.

What is claimed is:
 1. A roller bed that is inserted between idlers in aconveyor belt system, said roller bed comprising: a base plate orientedsubstantially parallel to said surface of said conveyor belt; a firstside plate on a first side of said base plate and oriented at an angleto said surface of said conveyor to support a first side of conveyorbelt and cause side of said conveyor belt to be angled upwards withrespect to a plane of said surface; a first plurality of rollers thatare affixed to a surface of said first side plate; a second side plateon a second side of said base plate and oriented at an angle to saidsurface of said conveyor belt to support a second side of said conveyorbelt and cause said second side of said conveyor belt to be angledupwards with respect to said plane of said surface; and a secondplurality of rollers that are affixed to a surface of said second plate.2. The roller bed of claim 1 further comprising: a third plurality ofrollers that are affixed to a surface of said base plate.
 3. The rollerbed of claim 1 further comprising: adjusting brackets connected to saidfirst side plate and said second side plate to change said angle oforientation of said first and second side plate.
 4. The roller bed ofclaim 1 wherein said adjusting brackets comprise: a base; a support thatextend upwards from said base; a movable attachment member that affixessaid first or said second side plate to said support at a desired angle.5. The roller bed of claim 1 wherein said movable attachment membercomprises: a plurality of openings in said support through which a screwis threaded.
 6. The roller bed of claim 1 further comprising: a mountingrail; couplings that affix said base plate, said first side plate, andsaid second side plate to said mounting rail.
 7. The roller bed of claim1 wherein said first side plate and said second side plate support saidfirst and said second sides of said conveyor belt against a skirting. 8.The roller bed of claim 1 wherein said first plurality of rollers andsaid second plurality of rollers are mounted with minimal space betweenthe rollers.
 9. The roller bed of claim 1 wherein rollers in said firstplurality of rollers and said second plurality of rollers are smaller indiameter than idlers.